GBS04S12 DC-DC Converter Technical Manual V1.0 Sixteenth-Brick DC-DC Converter 36 - 75 V Input 12 V Output 4.2 A Current Negative Logic Description The GBS04S12 is a new generation isolated DCDC converter that uses an industry standard sixteenth-brick structure, and features high efficiency and power density, operates from an input voltage range of 36 V to 75 V, provides the rated output voltage of 12 V and the maximum output current of 4.2 A. Operational Features     Input voltage: 36 - 75 V Output current: 0 - 4.2 A Low output ripple and noise Efficiency: 92.0% (12 V, 4.2 A) GBS04S12 Mechanical Features   Control Features Industry standard sixteenth-brick (L x W x H): 33.0 mm x 22.9 mm x 9.7 mm (1.31 in. x 0.90 in. x 0.38 in.) Weight: about 15 g Protection Features      Input undervoltage protection Output overcurrent protection Output short circuit protection Output overvoltage protection Overtemperature protection    Remote on/off Remote sense Output voltage trim Safety Features  (hiccup mode) (hiccup mode) (hiccup mode) (self-recovery) GLOBAL ENERGY EFFICIENCY SPECIALIST   UL60950-1 and CSA C22.2 No. 60950-1-07 Meet UL94V-0 flammability requirements RoHS6 compliant 1 Copyright©2014 Huawei Technologies Co., Ltd. All Rights Reserved. THIS DOCUMENT IS FOR INFORMATION PURPOSE ONLY, AND DOES NOT CONSTITUTE ANY KIND OF WARRANTIES. GBS04S12 DC-DC Converter Technical Manual V1.0 Designation Explanation GBS 1 04 2 S 3 12 4 1 — 48 Vin, high performance, analog control sixteenth-brick 2 — Output current: 4.2 A 3 — Single output 4 — Output voltage: 12 V EN41SACB on the label of the module is the internal model used by the manufacturer. Mechanical Diagram Pin Description Pin No. Function 1 Vin (+) 2 On/Off 3 Vin (-) 4 Vout (-) 5 Sense (-) 6 Trim 7 Sense (+) 8 Vout (+) 1. All dimensions in mm [in.] Tolerances: x.x ± 0.5 mm [x.xx± 0.02 in.] x.xx ± 0.25 mm [x.xxx ± 0.010 in.] 2. Pin 1-3, 5-7 are 1.00 ± 0.05 mm [0.040 ± 0.002 in.] diameter with 2.00 ± 0.10 mm [0.080 ± 0.004 in.] diameter standoff shoulders. Pin 4 and pin 8 are 1.50 ± 0.05 mm [0.060 ± 0.002 in.] diameter with 2.50 ± 0.10 mm [0.098 ± 0.004 in.] diameter standoff shoulders. GLOBAL ENERGY EFFICIENCY SPECIALIST 2 GBS04S12 DC-DC Converter Technical Manual V1.0 Electrical Specifications Conditions: TA = 25°C (77°F), Airflow = 1 m/s (200 LFM), Vin = 48 V, unless otherwise notes. Parameter Min. Typ. Max. Units Notes & Conditions Input voltage Continuous Transient (100 ms) - - 80 100 V V - Operating ambient temperature -40 - 85 ºC See the thermal derating curve Storage temperature -55 - 125 ºC - Operating humidity 10 - 95 % RH Non-condensing External voltage applied to On/Off - - 12 V - Operating input voltage 36 48 75 V - Maximum input current - - 2 A Vin = 0 - 75 V; Iout = 4.2 A No-load loss - 2.5 - W Vin = 48 V; Iout = 0 A Input capacitance 100 100 - µF Aluminum electrolytic capacitor Inrush transient - - 1 A²s - Input reflected ripple current (peak to peak) - - 30 mA Oscilloscope bandwidth: 20 MHz Output voltage set point 11.82 12.00 12.18 V Vin = 48 V; Iout = 4.2 A Output power 0 - 50 W - Output line regulation - - ±0.3 % Vin = 36 - 75 V; Iout = 4.2 A Output load regulation - - ±0.3 % Vin = 48 V; Iout = 0 - 4.2 A Regulated voltage precision - - ±3 % Vin = 36 - 75 V; Iout = 0 - 4.2 A Temperature coefficient - - ±0.02 %/°C TA = -40°C to +85°C (-40°F to +185°F ) External capacitance 220 220 2200 µF 220 µF: solid aluminum capacitor Output current 0 - 4.2 A - Output ripple and noise (peak to peak) - 50 200 mV Oscilloscope bandwidth: 20 MHz Output voltage Trim range 80 - 110 % - Output voltage overshoot - - 5 % The whole range of Vin , Iout and TA Output voltage delay time - - 100 ms From Vin connection to 10%Vout Output voltage rise time - 5 50 ms From 10%Vout to 90%Vout Switching frequency - 410 - kHz - Absolute maximum ratings Input characteristics Output characteristics GLOBAL ENERGY EFFICIENCY SPECIALIST 3 GBS04S12 DC-DC Converter Technical Manual V1.0 Electrical Specifications Conditions: TA = 25°C (77°F), Airflow = 1 m/s (200 LFM), Vin = 48 V, unless otherwise notes. Parameter Min. Typ. Max. Units Notes & Conditions Input undervoltage protection Startup threshold Shutdown threshold Hysteresis 32 30 1 34 32 2 36 34 3 V V V - Output overcurrent protection 4.62 - 6.72 A Hiccup mode Output short circuit protection - - - - Hiccup mode Output overvoltage protection 14.4 - 16.8 V Hiccup mode Protection characteristics 105 5 115 - 130 - °C °C Self-recovery The values are obtained by measuring the temperature of the PCB near the thermal resistor. Overshoot amplitude Recovery time - - 600 400 mV µs Current change rate: 0.1 A/µs load: 25% - 50% - 25%; 50% - 75% - 50% Overshoot amplitude Recovery time - - 800 400 mV µs Current change rate: 1 A/µs load: 25% - 50% - 25%; 50% - 75% - 50% 100% load 91.0 92.0 - % Vin = 48 V; Iout = 4.2 A 50% load 90.0 91.0 - % Vin = 48 V; Iout = 2.1 A 20% load 75.0 84.0 - % Vin = 48 V; Iout = 0.84 A - - 1500 V DC Basic Isolation Remote on/off voltage Low level High level -0.7 3.5 - 1.2 12 V V - On/Off current Low level High level - - 1.0 - mA µA - - 2.5 - Million hours Telcordia SR332; 80% load; Airflow = 1.5m/s (300LFM); TA = 40°C (104°F) Overtemperature protection Threshold Hysteresis Dynamic characteristics Efficiency Isolation characteristics Input-to-output Isolation voltage Other characteristics Reliability characteristics Mean time between failures (MTBF) GLOBAL ENERGY EFFICIENCY SPECIALIST 4 GBS04S12 DC-DC Converter Technical Manual V1.0 Characteristic Curves Figure 2: Power dissipation (TA = 25°C or 77°F) Figure 3: Thermal derating with airflow from Vin to Vout (Vin = 48 V; Vout = 12 V) Figure 4: Thermal derating with airflow from Vin(-) to Vin(+) (Vin = 48 V; Vout = 12 V) Air flow Figure 1: Efficiency (TA = 25°C or 77°F) Air flow Figure 5: Thermal plot with airflow from Vin to Vout (TA = 25°C (77°F); Airflow = 1 m/s (200 FLM); Vin = 48 V; Vout = 12 V; Iout = 4.2 A) GLOBAL ENERGY EFFICIENCY SPECIALIST Figure 6: Thermal plot with airflow from Vin(-) to Vin(+) (TA = 25°C (77°F); Airflow = 1 m/s (200 FLM); Vin = 48 V; Vout = 12 V; Iout = 4.2 A) 5 GBS04S12 DC-DC Converter Technical Manual V1.0 Typical Waveforms 1. During the test of input reflected ripple current, the input terminal must be connected to a 12 µH inductor and a 220 µF electrolytic capacitor. 2. Point B, which is for testing the output voltage ripple, is 25 mm (0.98 in.) away from the V out(+) pin. 25 mm (0.98 in.) 12 µH A 10 µF Tantalum capacitor B Vin(+) F1 Vout(+) Vout(+) Vin(+) Load DC-DC converter EMI filtering Vsource Vsource Vin(-) Load Sense(+) Co1 Cin On/Off S1 Co2 Trim Sense(-) Vout(-) Vin(-) 220 µF 100 µF 0.1 µF 220 µF Electrolytic capacitor Aluminum electrolytic capacitor Ceramic capacitor Solid aluminum capacitor Figure 7: Test set-up diagram Vout(-) Figure 8: Typical circuit applications F1: 3 A fuse (fast blowing) Cin: The high-frequency, low equivalent series resistance (ESR) aluminum electrolytic capacitor (100 µF) is recommended. Co1: The 1 µF ceramic capacitor is recommended. Co2: The 220 µF solid aluminum capacitor is recommended. Is Figure 9: Input reflected ripple current (for point A in the test set-up diagram, Vin = 48 V, Vout = 12 V, Iout =4.2 A) GLOBAL ENERGY EFFICIENCY SPECIALIST Vout Figure 10: Output voltage ripple (for point B in the test set-up diagram, Vin = 48 V, Vout = 12 V, Iout = 4.2 A) 6 GBS04S12 DC-DC Converter Technical Manual V1.0 Typical Waveforms Conditions: TA = 25°C (77°F), Vin = 48 V. On/Off On/Off Vout Vout Figure 11: Startup from On/Off Figure 12: Shutdown from On/Off Vin Vin Vout Vout Figure 13: Startup by power on Vout Iout Figure 15: Output voltage dynamic response (Load: 25% - 50% - 25%, di/dt = 0.1 A/µs) GLOBAL ENERGY EFFICIENCY SPECIALIST Figure 14: Shutdown by power off Vout Iout Figure 16: Output voltage dynamic response (Load: 50% - 75% - 50%, di/dt = 0.1 A/µs) 7 GBS04S12 DC-DC Converter Technical Manual V1.0 Remote On/Off Output Voltage Trim Logic Enable On/Off Pin Level Status The output voltage can be adjusted according to the trim range specification by using the Trim pin. Negative logic Low level On Trim Up High level or left open Off The output voltage can be increased by installing an external resistor between the Trim pin and the Sense(+) pin. On/Off On/Off Vout(+) Vin(+) Sense(+) Vin(-) Simple control Vin(-) On/Off Radj-up Trim Transistor control Load Sense(-) Vin(-) Vout(-) VCC On/Off Figure 19: Configuration diagram for Trim up TTL/ COMS On/Off Vin(-) Vin(-) Isolation control Direct logic drive The relationship between Radj-up and Vout: Radjup  Figure 17: Various circuits for driving the On/Off pin  Remote Sense This function is used to compensate for voltage drops on Rw. The Sense(+), Sense(-), Vout(+), and Vout(-) terminals should meet the following requirements: [Vout(+) – Vout(-)] – [Sense(+) – Sense(-)] ≤ 10% x Vnom (Vnom is the rated output voltage.) Vout(+) Rw Sense(+) Vin(-) Vout  Vnom 100 Vnom If the Trim pin is not used, it should be left open. Ensure that the actual output power does not exceed the maximum output power when raising the voltage. Trim Down The output voltage can be decreased by installing an external resistor between the Trim pin and the Sense(-) pin. Vin(+) On/Off 1. 2. 5.1 Vnom  (100  ) 510   10.2(k) 1.225    Load Trim Vout(+) Vin(+) Sense(-) Sense(+) Vout(-) Rw On/Off Figure 18: Configuration diagram for remote sense Vin(-) Load Trim Radj-down Sense(-) Vout(-) Rw indicates the line impedance between the output terminal and the load. Figure 20: Configuration diagram for Trim down If the remote sense function is disabled, the Sense(+) terminal directly connects to the Vout(+) terminal and the Sense(-) terminal directly connects to the Vout(-) terminal. GLOBAL ENERGY EFFICIENCY SPECIALIST The relationship between Radj-down and Vout: Radjdown  510  10.2(k)  8  Vnom  Vout 100 Vnom GBS04S12 DC-DC Converter Technical Manual V1.0 Input Undervoltage Protection MTBF The converter will shut down after the input voltage drops below the undervoltage protection threshold for shutdown. The converter will start to work again after the input voltage reaches the input undervoltage protection threshold for startup. For the Hysteresis, see the Protection characteristics. The MTBF is calculated according to the Telcordia, SR332 Method 1 Case3. Recommend Reverse Polarity Protection Circuit Output Overcurrent Protection Reverse polarity protection is recommended under installation and cabling conditions where reverse polarity across the input may occur. The converter equipped with current limiting circuitry can provide protection from an output overload or short circuit condition. If the output current exceeds the output overcurrent protection threshold, the converter enters hiccup mode. When the fault condition is removed, the converter will automatically restart. Figure 21: Recommend reverse polarity protection circuits Output Overvoltage Protection Recommended Fuse When the voltage directly across the output pins exceeds the output overvoltage protection threshold, the converter will enter hiccup mode. When the fault condition is removed, the converter will automatically restart. The converter has no internal fuse. To meet safety and regulatory requirements, a 3 A fuse is recommended. Vin(+) Vin(+) Vin(-) Vin(-) The fuse current should be 1.5 to 2 times the maximum operating current in actual use. Overtemperature Protection A temperature sensor on the converter senses the average temperature of the module. It protects the converter from being damaged at high temperatures. When the temperature exceeds the overtemperature protection threshold, the output will shut down. It will allow the converter to turn on again when the temperature of the sensed location falls by the value of Overtemperature Protection Hysteresis. GLOBAL ENERGY EFFICIENCY SPECIALIST 9 GBS04S12 DC-DC Converter Technical Manual V1.0 EMC For the acceptance standard, see the DC-DC Converter EMC Acceptance Manual. Figure 22: EMC test set-up diagram RV1,RV2: Varistor, 100 V, 4500 A D2: Gas discharge tube, 90 V, 10 kA CI1: Aluminum electrolytic capacitor, 100 µF CO1: Non-solid radial lead aluminum electrolytic capacitor, 2 x 470 µF CX1,CX2,CX3: Metalized film capacitor, 1uF, 275 V CY1,CY2: Metalized film capacitor, 0.1µF, 275 V CY3,CY4: Chip multilayer ceramic capacitor, 1000 V, 22 nF R1, R2: Chip thick film resistor, 1 W, 1Ω T1: Common mode inductor, single phase, 400 µH Qualification Testing Parameter Units Condition High Accelerated Life Test (HALT) 3 Low temperature limit: -60°C (-76°F); high temperature limit: 110°C (230°F); vibration limit: 40 G Temperature Humidity Bias (THB) 8 Maximum input voltage; 85°C (185°F); 85% RH; 1000 operating hours under lowest load power High Temperature Operation Bias (HTOB) 8 Rating input voltage; air flow:0.5 m/s (100 FLM) to 5 m/s (1000 FLM); ambient temperature between +45°C (+113°F) and +55°C (+131°F); 1000 operating hours; 50% to 80% load 8 Rating input voltage; air flow:0.5 m/s (100 FLM) to 5 m/s (1000 FLM); ambient temperature between -40°C (-40°F) and +85°C (+185°F); 1000 operating hours ; 50% load; temperature slope: 15°C (59°F) per minute; dwell time: 22 minutes Power and Temperature Cycling Test (PTC) GLOBAL ENERGY EFFICIENCY SPECIALIST 10 GBS04S12 DC-DC Converter Technical Manual V1.0 Thermal Consideration Thermal Test Point Decide proper airflow to be provided by measuring the temperature at part 1 in the Figure 23 to protect the converter against overtemperature. The Overtemperature protection threshold is also obtained based on this thermal test point. 1 Figure 23: Thermal test point Power Dissipation The converter power dissipation is calculated based on efficiency. The following formula reflects the relationship between the consumed power (Pd), efficiency (ŋ), and output power (Po): Pd=Po(1-η)/η Mechanical Consideration Installation Although the converter can be mounted in any direction, free airflow must be taken. Soldering The converter is compatible with standard wave soldering techniques. For wave soldering, the converter pins should be preheated for 20 to 30 seconds at 110°C (230°F), and wave soldered at 260°C (500°F) for less than 7 seconds. For hand soldering, the iron temperature should be maintained at 350°C (662°F) to 420°C (788°F) and applied to the converter pins for less than 10 seconds. The converter can be rinsed using the isopropyl alcohol (IPA) solvent or other proper solvents. HUAWEI TECHNOLOGIES CO., LTD. Huawei Industrial Base Bantian Longgang Shenzhen 518129 People's Republic of China www.huawei.com GLOBAL ENERGY EFFICIENCY SPECIALIST 11